Fabricating a one_piece metal vehicle wheel by hydro forming method

ABSTRACT

Hydro forming method for constructing a piece of vehicle wheel rims. The whole process will be implemented in seven stages. As the first station of raw sheet by the form Stretch a piece of cylindrical internal diameter sized the smallest inner diameter and the 1.6 height rim and this diameter is larger than the outer rim diameter. Secondly outer rim diameter cylindrical piece is the desired size trim. In the third and main stage action takes place hydro forming cylindrical piece by piece into a specific form of work (work piece) with no Punches final form and elasticity are required.

BACKGROUND OF THE INVENTION

Due to the ever increasing variety of complex industrial parts with process Production and the need for long and expensive development process parts that need to stretch and indirectly due to production constraints, as Some pieces are manufactured to prolong the production process and the result of it is the high cost of goods and reduce the quantity and quality of goods.

Therefore is possible with combining the various mechanisms in the production Hydro forming Components such as a piece of high strength and cost down.

In case the common methods for example producing vehicle wheels, designed and predicted facilities and Special devices that have been just depends on vehicle wheel are no other applications, however its universal facilities in innovative method and there is ability to change the line production. Conventional vehicle wheels production are not entitled to make of security and stability because such a variety of multi-piece and connections welding In addition to having a line expensive, long and special.

Hard to limit to arrive in terms of quality items such as balancing and also they are problematic appearance because some of the pieces, this problem are resolved using pieces of other parts of the hubcap wheel. Conventional vehicle wheels production are at least two pieces which contains the disc and rim is connected by welding and, and they haven't beauty appearance. Because in addition to having a piece of technical features and superior quality beauty is more specific with regard to the design of other there is no need hubcap, to use them.

SUMMARY OF THE INVENTION

Hydro forming: stretch forming indirectly by the fluid (oil Or water):

This method is capable to do elasticity and forms that other methods normally are not able to do it at high speed, super quality and low cost. In this method is done stretch forming sheet by liquid water (Combine the water and oil to prevent rust tooling and equipment which are here in after for short term water to apply) or oil.

The same fluidity factor is cause other benefits that they will be referred to

-   -   High speed production of special parts.     -   Precision and quality extra because the mechanisms used in this         method     -   Economically justified due to the very high cost long production         cycle compared to conventional methods.     -   Simply extend the process of manufacture vehicle wheel parts         Similar.     -   In the production process of high-speed piece another piece of.

Simply facilities and manufacture vehicle wheel equipment due to the specific complex technology and methods.

-   -   High-speed design and construction of a new piece.

Be noted that the application of this method can be used to produce all kinds of Pulley, vehicle wheel, Steel Vibrator petroleum industry and Petrochemical.

This is expressed in the cases cited above in detail:

A) Vehicle wheel is piece with tremendous impact on performance and safety. This piece two parts at least is produced all over the world, in some of automobile companies are being produced exclusively because use of special equipment exclusively. The production line equipment only vehicle wheel can be used to produce this piece despite the great capital allocation. This piece needs the long process because of several pieces and raw materials more. Cost is calculated at each step the cost of; as a result justify its high end of the price. It does not require fixed capital if the piece is produced by this method a piece. Because Can be summarized as Production Process in seven steps Because of less machinery and manufacturing space, and tips note that this equipment is not limited to, manufacture vehicle wheel and any other pieces can be produced from any type of industry.

B) This is a piece car's appearance, than it should be of considerable importance. Why is the use of a Buick hubcap on vehicle wheels, because the vehicle wheel pieces by welding connected that this welds is not a good view for appearance but it is necessary to use a Buick hubcap. But using provided a process for producing the vehicle wheel not requires transient welding. The vehicle wheel aesthetic appearance will be without the use of Buick hubcap.

C) Issues of interest and importance is vehicle wheel and tire weight. Since this weight does not include car auto spring suspension system, when dealing with bumps and other road deficiencies, more pressure enters to the system Vehicle suspension. So have the vehicle wheel and a lighter tire, we'll ride well and with greater acceleration and a vehicle wheel pieces due to the use of lighter material is less.

D) Lack of balance is in the presence parts of light or heavy tire cranking radial or axial, non-uniformity in the thickness of sheet used in vehicle wheel or on-uniformity in the thickness of ads. Two lack of balance occur due to heavy or light spots, that About the vehicle wheel because it produces a piece than there is not weld and there is uniformity in stretch the sheet Hydro forming method, it is completely dissolved in the both the lack of balance.

There is a major problem for cars that use the vehicle wheel sports cars cast aluminum; it is dry the vehicle wheel and its effect on the road accidents. This means that the vehicle wheel is shattered into several pieces by lama the same sometimes The same pieces is caused overturning cars because leverage under the car (due to the high speed still movement). But this problem is solved about the one.

Pace metal vehicle wheel itself and thus guaranteed car safety. Therefore, the specific achievements of the project in a nutshell noted the following:

-   -   There Is possible to produce parts that are not considered in         the design because of the lack of suitable methods     -   Significantly reducing production costs (Price reduced)     -   saving raw materials     -   Quality and extra strength due to one piece and remove unstable         welding processes     -   Enhance the visual appeal due to lack of welding and other         connections     -   Efficiency and high production rate due to the decline of the         manufacture vehicle wheel process     -   Use fewer and simpler equipment     -   Requires less fixed capital     -   No need for special machinery     -   Less manufacture space due to Reduce the manufacturing process.

Other applications of this design can be noted the following that different industries are produced the Several pieces:

A) automotive (parts such as vehicle wheel, different pulley, different Fuel tank . . . )

B) Petroleum and Petrochemical Industries (pieces like fitting vibrating . . . )

C) Defense Industry

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view and a plan view of the Primary piece For Production vehicle wheel that is drawn the Cylindrical.

FIG. 2 is an isometric view and a plan view of the cylindrical piece that the edge of diameter is trim.

FIG. 3 is an isometric view and a plan view of the vehicle wheel produced by the main process (hydro forming), that double-edged rim is shown.

FIG. 4 is an isometric view and a plan view of the vehicle wheel in addition Punch Valve hole.

FIG. 5 is an isometric view and a plan view of the vehicle wheel in addition Punch air holes.

FIG. 6 is an isometric view and a plan view of the vehicle wheel in addition Punch preservatives and center holes.

FIG. 7 is an isometric view and a plan view of the complete vehicle wheel by hydro forming method.

FIG. 8 is an isometric view and a plan view of the Open mode die, so work-piece is within the die for formation.

FIG. 9 is an isometric view and a plan view of the action mode die.

FIG. 10 is an isometric view and a plan view of the final action mode die.

FIG. 11 is an isometric view and a plan view of the final (open) mode die, so the vehicle wheel is final form.

FIG. 12 are Number of samples produced with this method, Included some examples of vehicle wheel and pulley.

LIST OF PARTS

-   1—Double edge -   2—Valve hole -   3—Air holes -   4—Preservatives holes -   5—Central hole -   6—Rod -   7—The fluid path -   8—Work piece -   9—Matrix -   10—Plate holder -   11—Jaws -   12—Ejector pins -   13—Hydraulic jacks

DETAILED DESCRIPTION OF THE

1—First, Initial Blanc is drawn to the size 1.3-1.6 of rim height according to the type and size of (vehicle wheel) and select initial blank, So that the diameter edges is larger for trim to the next stage (FIG.1).

2—Second, at this stage the diameter of the edge pieces first trim is (it is not uniform due to stretching process), due to the size bending radius of the outer edge of the rim diameter (FIG. 2).

3—At this stage that is the main stage and in fact Is technique invented, it done forming a piece by Hydro-forming method (FIG. 3). The die is mounted on a stretch hydraulic press. According to (FIG. 8) the upper part of the die includes rod 6 that it's a hole 7 in center is mounted to login fluid work piece 8. So that the fluid enters into the work piece being in terms of the amount is determined by a separate hydraulic unit, and then way back is located by a one-way valve that is the way. Next the operation will be explained, the fluid in the work piece has been removed from Parallel to the direction that it is a pressure valve (mechanical or electrical).

The below part of the die includes a matrix 9 that the final form of the flange (disc or hub) takes the form by fluid pressure. Plate holder 10 jaws 11 of die are installed on the ejector pins and they are surrounding matrix, that action format with downward moving jaws, Jaws die that are the sliding on the Plate holder that open and close by two hydraulic jacks 13 and the final form of rim will be finalized at wall of the jaws when the format operation by the fluid pressure. It is explained that the primary die for Prototype production we used instead of using hydraulic jacks Parties jaws of a mechanical arm and a ring of inhibitor Jaws closed during operation and at this stage we used hydraulic jacks for improving the efficiency.

Now according to a brief introduction, we will explain the mechanism. First must the course machine Jack down be set to the extent that ejector pins are placed in the holding plate parallel to the edge of the work-piece (FIG. 8), then start working the jaws closed into by hydraulic jacks both sides simultaneously. Fluid are simultaneously enters into the work piece so that work piece the overflow of fluid and then fluid flow as noted cuts by a valve that a path embedded and the fluid can back from parallel path that there is a pressure valve in the path, and simultaneously upper Jack Press moves downward the top part of the die (rod).

Involvement rod die with work piece beginning edge piece takes the form between the rod and the edge Jaws die and then continue to operate in the die whit resistance Jack down and the pressure valve (Adjusted as necessary to resist) against pressure of the upper machine jack. It is causing a lot of conflict between the rod and the work piece that this action sealing is caused between the work piece and the jaws, as a result, sealing will not allow the fluid to be removed and the continued dominance of pressure of the upper machine jack on the pressure button machine jack. Causes start moving jaws and plate holder jaws to down.

Since the work-piece is fixed on the matrix, work-piece fluid Pressure is compressed, as a result, this fluid pressure cause the work-piece is guided to the empty part of the die (The jaws and matrix forms) uniformly. More operation with the steady increase of pressure excess fluid on the press the end of the course and at the end of the operation the work-piece formation, rod is absolutely final forms work-piece on the matrix and all fluid on the work piece is removed from the pressure valve (FIG. 10) and at this time pressure switch command to return all die and machine parts to original position, for the next act (FIG. 11).

Therefore work-piece with the final 14 form is removed from the die and the die is ready for the next operation (FIG. 11). Thus, the one piece steel vehicle wheel whit a double edge 1 (FIG. 7) production is very strong. Whole process and the mechanisms it takes for 8 seconds. It is explanation the select type hydraulic press it depends on the type and size of the vehicle wheel and for vehicle wheel sizes 13 to 15 is appropriate hydraulic Press 800T.

According to FIG. 3 all the necessary forms created by fluid pressure also the fluidity is caused complete uniformity the whole process of stretch and forming and cause produce pieces whit high quality and on the other it will has unbalance lowest. Created a double edge on the rim and one piece with hub (disk) and remove unstable welding process is causes strength the pieces and according to the type of process It is clear that can be easily produced types of vehicle wheel with any type of model, geometry and offset.

4—In the fourth step, valve hole 2 is punched through a simple process Press and same hole use for reference to create vehicle wheel and retainer and air holes

5—In the fifth step, get references from the valve hole, air hole 3 punch and the edges of the form given (FIG. 5).

6—At this stage, mounting holes 4 and the center hole 5 in the vehicle wheel punching and forming (FIG. 6). It is necessary to explain the sensitivity and carefully in the punch holes is important due to the symmetry central and axial with rim.

7—At this stage, forming operation takes place on retainer holes (FIG. 7).

It is explained in the case is used of sheet material st12 or similar device to generate, we are need to coating the piece but if we use the stainless steel sheet material coverage is not required and the final piece is quality and shape super because has been removed all the technical weaknesses and apparent caused two pieces and welding the new product. work piece is removed from the pressure valve path. 

1. Fabricating a one-piece metal vehicle wheel by hydro forming method, comprising steps of: A die is mounted on a stretch hydraulic press; wherein an upper part of said die includes a rod comprising a hole in center, mounted to a login fluid work piece; wherein an amount of fluid entering into said work piece is determined by a separate hydraulic unit; wherein said fluid is directed inside said work piece via a one-way valve; a lower part of said die includes a matrix taking a final form of a flange (disc or hub) by pressure of said fluid; a plate holder having jaws are installed on an ejector pins, surrounding said matrix, wherein said jaws move downwards and slide on said plate holder via two hydraulic jacks; wherein said ejector pins are placed in said holding plate parallel to an edge of said work piece; said fluid simultaneously enters into said work piece overflowing it, then simultaneously an upper jack press moves downward on said upper part of said die; since said work-piece is fixed on said matrix, said work-piece fluid pressure is compressed, as a result, said fluid pressure causes a uniform removal of said die; where an entire process takes 8 seconds to complete. 